CN114829065A

CN114829065A - Robot repair control system and method

Info

Publication number: CN114829065A
Application number: CN202080081230.9A
Authority: CN
Inventors: 布雷特·R·黑梅斯; 马克·W·奥兰多; 丹尼尔·M·博迪利; 乔纳森·B·阿瑟; 内森·J·赫布斯特; 托马斯·J·施特赖; 阿龙·K·尼纳贝尔
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2019-11-27
Filing date: 2020-11-24
Publication date: 2022-07-29
Also published as: EP4065312A1; MX2022006248A; JP2023503609A; WO2021105865A1; US12097528B2; US20230001448A1

Abstract

A repaired area on a working surface is presented herein. The repaired area includes a repair boundary. Within the repair boundary, the working surface has a repair texture, and outside the repair boundary, the working surface has a working surface texture. The repaired area also includes a repair depth distribution within the repair boundary and hidden features. The repaired area is the result of performing a robotic repair on the work surface to remove the defect.

Description

Robot repair control system and method

Background

Varnish coating repair is one of the last operations to be automated in the automotive Original Equipment Manufacturing (OEM) sector. Techniques for automating this process, as well as other paint applications suitable for inspection and repair using abrasives and/or robotics (e.g., primer sanding, varnish coating defect removal, varnish coating polishing, etc.), are desired.

Early work to automate the detection and repair of paint defects included the system described in U.S. patent publication 2003/0139836, which discloses the use of electronic imaging to detect and repair paint defects on vehicle bodies. The system references the vehicle imaging data with the vehicle CAD data to form three-dimensional paint defect coordinates for each paint defect. The paint defect data and paint defect coordinates are used to develop repair strategies for automated repair using a plurality of automated robots that perform a variety of tasks, including sanding and polishing paint defects.

Drawings

In the drawings, which are not necessarily drawn to scale, like numerals may describe like parts throughout the different views. The drawings are generally shown by way of example, and not by way of limitation, to the various embodiments discussed in this document.

FIG. 1 is a schematic diagram of a robotic paint repair system in which embodiments of the present invention are useful.

Fig. 2 is a schematic diagram of a paint repair robot that may be used with embodiments of the present invention.

FIG. 3 illustrates a method of robotic defect repair according to an embodiment of the present invention.

Fig. 4A to 4B are images of defects that may exist on a vehicle.

FIG. 5 illustrates variables of interest in a robotic paint repair system.

Fig. 6A-6D illustrate exemplary pressure responses that may be used in embodiments of the present invention.

Fig. 7A-7C illustrate exemplary orientations that may be useful in embodiments of the present invention.

Figure 8 shows the pressure profile of the orbital sander.

Fig. 9A-9B illustrate velocity profiles of rotary and orbital sanders.

Fig. 10A to 10C show shapes that can be used as a basis for a robot repair trajectory in an embodiment of the present invention.

11A-11B illustrate an orientation and force profile of a trajectory according to an embodiment of the present invention.

Fig. 12 shows a diagram of a repaired work surface according to embodiments described herein.

FIG. 13 illustrates a repair policy generation system according to embodiments described herein.

FIG. 14 illustrates a method of generating a repair instruction in an embodiment of the invention.

Fig. 15 is a repair policy generation system architecture.

Fig. 16 to 17 show examples of mobile devices that may be used in the embodiments shown in the previous figures.

FIG. 18 is a block diagram of a computing environment that may be used in the embodiments shown in the previous figures.

Fig. 19 to 24 show images and analysis of defects described in further detail in the examples.

Detailed Description

Recent advances in imaging technology and computing systems have made the process of varnish coating inspection feasible at production speeds. In particular, the stereo-deflection method has recently been shown to provide images and locations of paint and varnish coating defects, as well as spatial information (providing coordinate location information and defect classification) with appropriate resolution to allow for subsequent automated spot repair.

As used herein, the term "vehicle" is intended to encompass a wide range of moving structures that receive at least one paint or varnish coating during manufacture. While many of the examples herein relate to automobiles, it is expressly contemplated that the methods and systems described herein are also applicable to trucks, trains, boats (with or without motors), airplanes, helicopters, and the like.

The term "paint" is used herein to broadly refer to any of the various layers of the vehicle that have been applied during the finishing process, e.g., an electrophoretic paint, filler, primer, paint, clear coat, etc. In addition, the term "paint repair" relates to locating and repairing any visual artifacts (defects) on or within any one of the paint layers. In some embodiments, the systems and methods described herein use a clear coat as the target paint repair layer. However, the proposed system and method is applicable to any specific paint layer (e.g. electrophoretic paint, filler, primer, paint, clear coat, etc.), with few modifications.

As used herein, the term "defect" refers to an area on a work surface that interferes with the visual aesthetics. For example, many vehicles appear shiny or metal-like after finishing painting. "defects" may include debris trapped within one or more of the various paint layers on the work surface. Defects may also include smudges in the paint, excess paint including streaking or dripping, and indentations.

Paint repair is one of the last remaining steps in the vehicle manufacturing process, still largely manual. Historically, this has been due to two major factors, the lack of adequate automated inspection and the difficulty of automating the repair process itself. Paint and varnish coating repair standards are related to aesthetics as judged by the human eye (the dealers who accept the vehicles and the end customers who inspect the vehicles prior to purchase). Traditionally, robots are designed to provide "perfect" or highly "regular" repairs, with clear, defined edges and uniform cuts (see fig. 4B). Unfortunately, this results in the repair being highly visible to the human eye. The systems and methods described herein present ways to increase the irregularities of the paint repair process so that repaired defects are better mixed into the vehicle surface and less detectable by the customer.

FIG. 1 is a schematic diagram of a robotic paint repair system in which embodiments of the present invention are useful. The system 100 generally includes two units, a vision inspection system 110 and a defect repair system 120. Both systems may be controlled by

motion controllers

112, 122, respectively, which may receive instructions from one or more application controllers 150. The application controller may receive input or provide output to the user interface 160. The repair unit 120 includes a force control unit 124 alignable with an end effector 126. As shown in FIG. 1, the end effector 126 includes two tools 128, as further described in co-pending application Nos. 62/940,950 and 62/940,960. However, other arrangements are also explicitly contemplated.

The first of the two main challenges, namely the inspection of the vehicle 130 by the inspection unit 110, is of interest due to the nature of the potential problem domain. Generally, the surface of interest is very large compared to the defect itself, with differences of many orders of magnitude. This results in a compromise between field of view and resolution when sensor selection is involved. In addition, each paint layer (e.g., electrophoretic paint, primer, paint, clear coat, etc.) of the finishing process differs in its visual appearance, with specular reflectivity being particularly noticeable. Highly specularly reflective surfaces (i.e., high gloss) pose unique imaging challenges. These problems together make inspection difficult. Over the past few years, recent advances have been made in the field with increasing computing resources, resulting in the availability of several business solutions. The presence of a sufficiently capable inspection system 110 is important to identify defects repaired by the repair unit 120.

The current state of the art in vehicle paint repair is the use of fine grinding and/or polishing systems to manually sand/polish defects with or without the aid of electrical tools while maintaining a desired finish (e.g., matching specular reflectivity in a clear coat). Professionals performing such repairs utilize many hours of training while utilizing their senses to monitor the progress of the repair and make changes accordingly. This complex behavior is difficult to capture in robotic solutions with limited sensing.

In addition, abrasive material removal is a pressure driven process, while many industrial manipulators typically operate naturally in an orientation tracking/control state and are optimized for orientation accuracy. The result is an extremely accurate system with an extremely rigid error response curve (i.e., small azimuthal displacement results in very large correction forces) that is inherently poor under force control (i.e., joint torque and/or cartesian forces). Closed loop force control methods have been used to address (with limited utility) the latter along with newer (and more successful) force control flanges that provide soft (i.e., non-rigid) displacement curves more suitable for sensitive force/pressure driven processes. However, the problem of robust process strategy/control still exists and is the focus of this work.

Fig. 2 is a schematic diagram of a paint repair robot that may be used with embodiments of the present invention. In some embodiments, the robotic repair unit 200 has a base 210, which may be stationary. In other implementations, the base 210 may be moved in any of six dimensions, translation, or rotation about the x-axis 212, y-axis 214, and/or z-axis 216. For example, the robot 200 may have a base 210 secured to a rail system configured to travel with a vehicle being repaired. Depending on the defect location, the robot 200 may need to move closer to or further away from the vehicle, or may need to move higher or lower relative to the vehicle. The movable base 200 may make it easier to repair defects that are difficult to access.

The robotic repair unit 200 has one or more tools 240 that can interact with a work surface. In one embodiment, the tool 240 may include a back-up pad 250, or another suitable abrasive tool. During the abrading operation, the tool 240 may have an abrasive disc or other suitable abrasive article that is attached using an adhesive, hook and loop, a clamp system, vacuum, or other suitable attachment system. However, when the abrasive article is moved in conjunction with the back-up pad 250 to which it is attached, the abrasive article is not necessarily considered to add an additional degree of freedom to the movement of the robotic repair unit 200. When installed to the robotic repair unit 200, the tool 240 has the ability to be positioned within the degrees of freedom (in most cases 6 degrees of freedom) and any other degrees of freedom (e.g., the compliance force control 230 unit) provided by the robotic repair unit 200, the frame of reference of which is depicted by

axes

252, 254, and 256.

The support pad 250 is coupled to the tool 240 with a rail that provides some additional degrees of freedom. In most tools, a single degree of freedom is provided by a rotational axis with or without some offset. The support pad 250 reference frame is depicted by

axes

252, 254, and 256. The tool 240 axis frame of reference is depicted by

axes

242, 244, and 246. Tool 240 is coupled to force control 230 unit output. The force control flange 230 provides a soft (i.e., non-rigid) displacement curve. In most force control units, a single degree of freedom is provided by a sliding (prismatic) joint along the axis of motion. The force flange output reference frame is depicted by

axes

222, 224, and 226. Force control 230 unit is coupled to flange 220. The movements of the

components

210, 220, 230, 240, and 250 may all be controlled using a robot controller (e.g., the robot controller 122 shown in fig. 1) and/or some auxiliary controls (e.g., the application controller 150).

The orientation of a particular abrasive particle in the context of an abrasive article coupled to back-up pad 250 may be calculated by: the position of the abrasive particles (as a fixed point in the support pad's reference frame) is mathematically transformed in time into some other desired reference using a series of relative transformations between the above-described component reference frames (shown below in equation 1 relative to the base 210 reference frame).

The movement (M) of the support pad 250 reference frame relative to the stationary base 210 over time is affected by: movement of the flange 220 over time (e.g., robotic macro motion) as reflected in the first term, movement of the force control 230 over time (e.g., compliant linear displacement) as reflected by the second term, movement of the tool 240 over time (e.g., shaft rotation) as reflected by the third term, and rotation of the support pad relative to the tool 240 over time. The first, second, and third terms indicate repair trajectories, as discussed in more detail below. The fourth item indicates rotational movement of the support pad 250 (e.g., passive rotation on a random orbital arrangement). Describing and controlling complex movements is necessary to manage the repair process.

FIG. 3 illustrates a method of robotic defect repair according to an embodiment of the present invention. Method 300 is an overview of how a robotic repair system according to at least some embodiments described herein repairs a defect.

For example, in block 310, instructions are received from a robot controller (such as application controller 150 in fig. 1). For example, the instructions include movement instructions for different components of the robotic repair unit (such as

components

210, 220, 230, 240, and 250 of fig. 2).

In block 320, the robotic motion controller moves the abrasive article mounted to the tool into position to prepare for the engagement defect. The location of the defect on the vehicle is known from the inspection system. Moving the abrasive article into position includes moving the article to at or near the top of the defect. This orientation may be referred to as a nominal pose of the support pad.

In block 330, the abrasive article engages the defect. The bonding defect may include sanding the defective area, as indicated in block 332, or polishing the defective area, as indicated in block 334. The bonding defect also includes changing different repair parameters of the support pad relative to the nominal pose, such as velocity 332 of the support pad, force 334 applied to the support pad, offset orientation 336 of the support pad, and final repair shape 338 resulting from the sanding and polishing operations.

In block 340, the defective area is cleaned. Cleaning may include wiping off any fluid used in sanding or polishing, as well as wiping off debris. After the cleaning step, the tool may re-engage the defect, as indicated in block 342. For example, a dual installation tool system may have a sanding unit and a polishing unit available so that after cleaning is achieved, the next repair step can be achieved.

In block 350, the defective area is inspected to determine if the repair is sufficient. If additional repairs are needed, the method 300 may receive a new instruction, as indicated by arrow 360, and the method may repeat. Inspecting the defect repair may include capturing a repaired image 352, which may be presented to a repair operator or saved as needed. The inspection may also include verifying the repair, as indicated in block 354, which may include comparing the pre-repair and post-repair images, detecting whether the defect will be visible/perceptible to the human eye, or another suitable verification technique.

Fig. 4A to 4B are images of defects that may exist on a vehicle. Fig. 4A shows a raised defect 410 on a working surface 400. The raised defect 410 may be caused by debris trapped under one or more paint layers on the working surface 400. Also of note is texture 420 on the work surface 400. When paint is applied to a work surface in a manufacturing environment, environmental disturbances (such as movement or vibration of the vehicle, movement of the circulating air, and the nature of the applied paint) result in the textured surface 420, which is commonly referred to as "orange peel" due to its appearance. Orange peel may also be intentionally added to the clear coat surface to texturize different levels of orange peel and increase the aesthetic appearance of different surfaces of the vehicle.

Unfortunately, repairs made on a work surface with orange peel will destroy the texture and may produce a highly visible repair area, as shown in image 450. The restoration in fig. 4B clearly shows the rounded profile 458 with the abrasive article contacting the surface. Additionally, the inner circle 454 is an artifact of the repair strategy. Between the centers 452 of the repair areas, a wave effect is shown due to the force profile, where the surface height decreases from the center 452 to the circle 454, rises again to the high point 456, and then falls again to the edge 458. The force profile may be understood to be similar in shape to a "doughnut cake" in that a higher pressure is applied in an annular region within the perimeter of the disk. The desired restoration smoothly blends the polished surface with the orange peel around the edge of the restoration to produce a feathered result.

Generally, it is desirable to "perfectly" repair any defects present in the paint, however, the concept of perfect repair is largely subjective and thus no formal definition can be given. Informally, a "perfect" repair is one in which the end result is visually indistinguishable to the human eye from otherwise non-defective areas of the working surface, and the concept of an optimal repair is considered to refer to the best possible repair given some starting conditions. For example, not all defects may be repaired to a perfect state. In addition, time is a critical parameter for defect repair, as vehicle manufacturing is typically an assembly line process. Effective repair can then be characterized as repair that makes the defect area indistinguishable in as short a time as possible.

The human eye is very good at noticing essentially "perfect" or "regular" items and abrupt transitions in boundaries or textures. This sensitivity to sudden visual boundary transitions requires control of the transition between repaired and unrepaired areas. Repairs such as that shown in fig. 4B are highly visible for a number of reasons, including the nearly perfectly circular nature of the repair perimeter 458 and the annular central depression 452. In the former case, such a transition results from a change in surface texture, i.e. from the original paint texture (often referred to as orange peel due to its appearance) to a generally smoother polished repaired area, while in the latter case such a transition results from a change in the height of the surface caused by the distribution of material removal during the repair process. Generally, it is not possible to remove defects without some local change in surface texture and/or height. That is, there is utility in a method of sufficiently repairing defects while leaving as few changes as possible, and the changes left make it difficult for the human eye to notice them. In this regard, we aim to maximize the concealment of defect repairs on the finished article. As described herein, hidden features are those features that reduce the visual acuity of the repair and are therefore less likely to be noticed by the human eye. Hidden features may include, for example, feathering around the boundary edge, uneven repair area, repair depth profile, uneven cut rate, and the like.

A cut modeling driven approach to derive a repair strategy is proposed that aims to reduce the resulting visual appearance of defect repair while managing boundary transitions. It is important to note that care needs to be taken not to increase the perceived defects during the repair of the original defects. In some embodiments, the repair strategy begins by identifying the desired characteristics of the cut distribution (i.e., the nature of sufficiently removing defects while also exhibiting other desired hidden characteristics (such as mixing/feathering)) and finding the robot motions that result in the distribution. Such an approach is possible by using a predictive cutting model of the abrasive/substrate interaction based on first principles and supplemented with measurements. Further discussion is provided below with reference to fig. 5.

The methods and systems herein operate under the assumption that the substrate is locally planar. This assumption does not lead to a loss of generality, since a more complex model taking into account the substrate geometry enables the same method to be applied to locally non-planar surfaces. Such models are possible and are contemplated in some embodiments herein. In general, defects may be present at any depth in any one of the paint layers, and may take various forms, including: pits, hair, scratches, dust bumps, drops, fish eyes.

One basis for understanding material removal (and a good first approximation) is the well-known Preston's equation of material removal (equation 2 below), which expresses the instantaneous rate of material removal (cutting) as the product of pressure, relative velocity, and a constant (Preston's constant) defined in part by the complex interaction between the abrasive, the substrate, and any cutting fluid.

Where k is _p Is a constant dependent on the abrasive/surface interaction, p is the pressure at any given point on the surface, and v _rel Is the relative velocity of the abrasive and the surface at that point. Item(s)

Is the rate at which material is removed. According to equation 2, and the abrasive and any cutting fluid are predetermined and held constant for the duration of the defect repair (i.e., k _p Fixed), the domain-specific inputs for instantaneous cutting are the applied force (and resulting pressure) and tool speed (rotation, orbit, etc.). The total cut is determined via an integral of the instantaneous cut over time, which is accordingly distributed as a function of any macroscopic motion of the robot to the end effector.

In this regard, the removed material on the surface may be expressed as an integral of the pressure distribution on the abrasive media (resulting from the interaction with the substrate) scaled by the relative velocity between the abrasive and the substrate and the Preston constant. Here, we note that the pressure distribution is largely dependent on the applied force, but also on the relative attitude of the abrasive/back-up pad and the substrate (i.e., it is geometric in nature). Is provided with

X(t):＝[X _p (t),X _o (t)]Equation 3a

To have an orientation (X) _p ) And orientation (X) _o ) The path of the robotic repair of the component(s). Then the cut (x) at a certain point on the substrate can be expressed as:

where x is the point of interest on the substrate in some fixed reference frame, an

Is the distance from the tool center point to the point of interest as represented in a reference frame centered on the tool center point (from which the pressure and velocity profiles are defined). Equation 3b provides the material removed at a point on the substrate x after performing the repair strategy comprising the robot motion path (x (t)).

The pressure and relative velocity profile terms are the orientation (X) of the tool _o(t) ) Is also a function of time (force can be controlled in time, which changes the pressure profile, speed can also change in time with the rail and/or rotary tool speed). The outputs of these profiles are the pressure and velocity at the point of interest (x) at time t. Constant term k _p Adjusting between repairs as disk life decreases. In our following modeling, we assume that this is constant over the lifetime of a single repair. These terms are integrated over time to yield the total cut at that point. Thus, the remaining steps are to find and generate the appropriate pressure profile p (x, t) and macroscopic motion x (t) of the end effector tool, depending on the desired result. Both adequately remove defects while leaving as little visual impact as possible for the purposes of creating a repair as described above. Creating an irregular boundary between the repaired surface and the unrepaired surface makes the repair less visible to human inspection.

FIG. 5 illustrates variables of interest in a robotic paint repair system. Variables in the system 500 may be manipulated to effect irregularities in the robotic repair. Variables can generally be broken down into controllable variables 550 and dynamic constraints 560. The controllable variables 550 include variables that can be set by the robot controller. Dynamic constraints are caused by controllable variables or are limits set on the robot itself, such as maximum acceleration, velocity or applied force. The dynamic constraints are either generated by controlled variables,

the trajectory variable 510 includes controllable values for the position 502 and the orientation 504. The orientation 502 of the support pad may be defined in coordinate space (x, y, z). The orientation 504 of the support pad may be defined by roll, pitch, and yaw (r, p, y). For example,the support pad may be positioned flush with the work surface or may be inclined at an angle relative to the workpiece. The trajectory variables may be programmed to adjust during repair. For example, the support pad may be in a first orientation (x) from a first time ₁ ,y ₁ ,z ₁ ) A second position (x) moved to a second time ₂ ,y ₂ ,z ₂ ). Similarly, the orientation (r, p, y) may be changed from a first point in time to a second point in time. This results in a dynamic pose u (t) that changes over time. Pose is defined as the relative orientation and relative orientation of the back-up pad with respect to the team surface of the work the abrasive is doing. The pose may position the back-up pad in perfect surface alignment with the work surface, or the pose may be offset to allow different types of contact with portions of the abrasive.

Tool variables 530 may also change during the repair. For example, the effective force 506 applied to the support pad may be varied over time. Additionally, the rotational speed 508 of the support pad may also be varied. For example, in the case of a random orbital tool setting to perform a circular repair, it may have a first rotational speed and/or force when moving between 0 ° and 90 ° of the circular repair motion and a second speed and/or force in the range of 90 ° to 360 ° of the circular repair motion. In another example, it may have a first speed for the first two seconds of movement and a second speed for the last six seconds of movement.

The robotic motion combined with the rotational/orbital motion of the tool produces a relative velocity 566 between the abrasive media and the substrate over time. However, we note that in practice the speed of the robot (macro motion of the tool) is on a scale that is typically at least an order of magnitude slower than the rotation speed 508, and is therefore typically negligible when calculating instantaneous cuts in the presence of a power tool. However, the dynamic pose u (t) may be considered if necessary. The combined controlled force 506 and trajectory variable 510 also generate a dynamic pressure 564 over time due to the abrasive/back-up pad interaction.

In fact, the tool variables cannot change immediately and are bounded by dynamic constraints. Therefore, any trajectory variables 510 and tool variables 530 must take into account the dynamic constraints of the tool and robot.

While the trajectory variables 510 and tool variables 530 may be adjusted during the repair, the geometry variables 520 are typically only exchanged between repairs. For example, the support pad 522 has a given diameter that remains constant during repair. Similarly, the rails 524 of the tool attached to the support pads 522 are also set prior to repair, and typically only change between repairs. The substrate surface 526 is also limited because it is a function of the location of the defect on the vehicle body. The geometric variable 520 also contributes to the experienced pressure 564 over time.

Together, the trajectory variables 510, geometry variables 520, and tool variables 530 all produce a set of repair properties 570 for a given repair. In some embodiments, it is desirable for at least one repair property 570 to contribute in some form to the concealment of repairs. In some embodiments, the plurality of characteristics 570 contribute in some way to the hiding of the repair.

Repair boundary 572 generally refers to the perimeter of the repair. Many current robotic repairs are circular, as shown in fig. 4B. In other words, they have a constant radius extending from the center of repair. In contrast, non-circular boundary 572 refers to a boundary having some non-constant radius. Non-circular boundaries are a form of concealment because they are generally less perceptible in many scenes. Some examples include rotationally symmetric (periodic) shapes, such as ellipsoids, stars, etc.; non-periodic and/or random shapes, with no symmetry (rotational, radial, bilateral or in other forms); and generally arbitrary (open) curves.

In particular, we exploit rotational symmetry. The n-order rotational symmetry (i.e., n-fold rotational symmetry with respect to the origin or axis means an angle of rotation of 360/n (30, 60, 90, 120, 180, etc.)) does not change the repair pattern. "1-fold" symmetry is not considered symmetrical by this definition because a 360 rotation does not actually rotate the shape. Some examples include ellipses and lemniscates (2-fold), squares (4-fold), some petal-shaped curves, etc. The circle is effectively infinitely heavy (i.e., any rotation results in the same shape).

The repair volume 574 refers to the volume of the working surface (i.e., substrate material) removed. Generally, this may be specified as the total volume or more usefully as the volume distribution of the removed material (i.e., the depth of cut as a function of substrate orientation). The above examples of hidden features extend naturally from the above repair boundary case to the prosthesis distribution, such as symmetry and the like. In addition, we consider contours cut on some regions of interest. For example, the depth of cut is a function of distance from the center of the repair or defect location. Here, the hidden form may be expressed as a mathematical functional property such as monotonicity, convexity, or the like.

One example of a volume hiding strategy is feathering 576, which involves a gradual decrease in the depth of cut with distance from the defect. Feathering 576 or blending refers to a technique that makes the outer edges or boundaries of the repair less visible and "blends" into the orange peel. Some examples of feathering are shown in fig. 19-23.

Other (hidden) properties 578 of the repair can also be introduced by changing different controllable variables 550.

With respect to pressure distribution, closed cell foam may be approximated as a spring damper of a single support pad. For example, if we assume that the support mat is made of foam and the compression (displacement) is kept relatively low, we can assume a fixed pressure profile for each mat configuration and model the pressure profile as described in fig. 6 below.

Fig. 6A-6F illustrate exemplary pressure responses that may be used in embodiments of the present invention. Fig. 6A-6D all illustrate how a tool 610 (such as a back-up pad) may interact with a working surface 600, and the resulting experienced pressure 620 along a cross-section of the back-up pad. Schematic pressure profiles demonstrating various support pad and substrate interface configurations are shown for the rigid support (6A) and deformable support (6C). In the top image, the support pad is aligned with the substrate plane when fig. 6B and 6D are tilted by some non-zero offset. For all cases, the force is applied perpendicular to the support pad support. The example of fig. 6B can be modeled with

equations

4 and 5 below.

Where u and v represent coordinate positions as represented in a reference frame positioned at the abrasive center point and are oriented such that u points along the surface in an oblique direction.

The following conditions are met:

∫∫p(u,v)dudv＝f _{tool with a locking mechanism} Equation 5

Fig. 7A-7C illustrate exemplary orientations that may be useful in embodiments of the present invention. As shown in fig. 6A-6E, the support pad may be angled with respect to the work surface. Fig. 7A-7C illustrate different inclinations of the support pad with respect to the surface that are possible. Fig. 7A shows a normal tilt 700 with the support pad flush with the work surface. Fig. 7B shows an outward lean 720 and fig. 7C shows an inward lean 730. However, while each of the

inclinations

700, 720 and 730 is shown as being constant for the entire rotation of the circle, it is expressly contemplated that the orientation of the support pad may vary within a given rotation, thereby introducing desired irregularities into the repair.

Figure 8 shows the pressure profile of the orbital sander. Several different tools are available for grinding operations, including vibratory, rotary, orbital, and random orbital sanders. The orbital sander moves in a circular motion as shown in fig. 8. The random orbital sander also includes passive rotation of the back-up pad. Random orbital sanders can leave less vortex pattern on the surface due to the additional random rotation. For ease of understanding, fig. 8 illustrates the motion of the orbital sander, however, random orbital sanders are expressly contemplated herein as providing an additional variable of the passive rotational speed of the support mat.

Fig. 8 also shows how the effective tool pressure distribution can be modeled for equations 3a and 3b above. The effective pressure generated by the tool motion is considered to be the time average of the pad pressure profile over the tool's range of motion. For this example, for a (random) rail tool with a rail radius of one third of the shoe radius, the shoe pressure distribution is shown at the top right, and the effective tool pressure distribution is shown at the bottom right.

FIG. 8 illustrates the movement of the orbital sander 800 with a given disc pressure 840 and a resulting disc pressure 850. The orbital sander 800 has a known orbital radius 810, a support pad radius 820, and a resulting effective radius 830 for the affected workspace region. This results in a higher effective disc pressure at the center of the larger affected area and a lower effective disc pressure near the edges. The effective disc pressure may be manipulated over the entire repair area to introduce hidden features into the repair characteristics. Higher pressures are associated with higher material removal. Moving the orbital sander over the repair surface can introduce hidden volume features and hidden boundary features to the repair.

Fig. 9A-9B illustrate velocity profiles of rotary and orbital sanders. A schematic of the abrasive characteristic speeds for the rotational and orbital settings is shown in fig. 9A and 9B, respectively. The velocity vectors are depicted by

arrows

920 and 960, respectively. The rotary sanding unit has a radius 910 and is configured to rotate in a direction 940, thereby creating a velocity profile as shown by arrow 920. The outer edges of the rotary sander 900 have a higher speed than the interior of the rotary sander.

Orbital sander 950 has a tool area 952 that is smaller than the effective tool area 972. Orbital sander 950 has an orbital radius 962 and rotates in direction 964, resulting in speed 960. Orbital sander 950 rotates in direction 974.

The robotic repair unit may know what abrasive tools are present on the tool and what abrasive material grades are present for a given repair. Additionally, in some embodiments, the robotic repair unit also has an indication of the remaining life of the abrasive disc or the effectiveness of the abrasive. Knowing the details about the abrasive material and what kind of tool is coupled to the robotic arm allows even more control over the final repair. While two types of abrasive tools are shown in fig. 9A and 9B, other abrasive tools are also known and contemplated for use in at least some embodiments.

Fig. 10A to 10C show shapes that can be used as a basis for a robot repair trajectory in an embodiment of the present invention. Many current robotic repair units rely on a circle for generating the repair, typically rotating the abrasive disc about a single point to remove the defect. As described above, and as shown in fig. 4B, this results in a repair that is "too regular" and perceptible to the human eye. Other shapes and designs have been explored to determine what other designs may be affected by the robotic repair unit without resulting in a circular repair area.

For example, the following curves can be used to generate repair features that are sufficiently irregular and therefore hidden: bean curves, butterfly curves, eight curves, ellipses, lobate lines (bilobed lines, trilobed lines, quadrilobate lines, etc.), heart curves, oval curves, lemniscates, radial spirals, spirals (archimedean spirals, costas, fermat spirals, hyperbolas, etc.), hyperellipses, trochoid lines (epitrochoid, hypocycloid, epicycloid, etc.), logarithms, rosettes, etc.

A series of shapes of particular interest are the cycloids of the inner and outer cycloids, which may be formed by the robotic repair unit using the variables as shown in diagram 1000 of fig. 10A, in accordance with equations 7 and 8 below. Some exemplary shapes obtained in this manner are shown in table 1010 of fig. 10B.

FIG. 10C shows another set of shapes, referred to herein as "rose line" shapes 1020. The rose line shape 1020 may be obtained using equation 9 below:

r ═ a sin (n θ) + b equation 9

The general rose shapes 1020 are each shown with an associated value of n. The coefficients (a, b) may be used for the stretched or expanded shape, respectively.

Note that rose lines, along with circles, arcles, and epicycloids/hypocycloids are special cases of epitrochoids/or hypocycloids (i.e., can be represented via careful selection of a, b, and h).

Fig. 11A-11B illustrate a repair trajectory and resulting material removal (cutting) profile according to an embodiment of the present invention. As shown in the comparison between table 1100 and table 1150, combining the shape and inclination of the support pad may result in very different material removal profiles. Each shape in Table 1100 corresponds to a rose line with an n value of 2, 3, 4, or 5, and an inclination of-5, 0, or 5. The resulting material removal profile is shown in fig. 11B. As shown in fig. 11B, a rose-line based (and thus epitrochoid/or epitrochoid) trajectory can focus abrasive removal on a defect region while also changing the removal volume on the repair region. This results in a better mixing of the repair into the surrounding orange peel on the working surface via irregularities.

Such tracks provide significant concealment flexibility. As an example, the cut profile 1152 of fig. 11B shows defect modification (in an area smaller than the support pad diameter) and a smooth transition between the defect modification and the surrounding area. The cut distribution 1154 of fig. 11B shows a "doughnut-cake" shaped repair that exhibits smooth feathering and non-circular rotational symmetry (8-fold rotational symmetry in this case) as a hidden feature.

Fig. 12 shows a diagram of a repaired work surface according to embodiments described herein. The working surface 1200 has an orange peel texture that the sanded area 1250 is attempting to blend. The abrasive disc attached to the back-up pad has a center 120 and is movable along the work surface 1200 as indicated by

directions

1212 and 1214. In the embodiment shown in fig. 12, the support mat is attached to a random orbital sander that is also movable in the directions indicated by

arrows

1222 and 1224.

The repair trajectory 1230 is shown as having an irregular shape that does not correspond to a regular polygon. Repair trajectory 1230 has a plurality of curves and convex indentations that result in repair area 1250 having an irregular perimeter. Fig. 12 illustrates a support pad having an inclined orientation, resulting in a pressure gradient being applied over an area contacting the working surface 1200 of the support pad at a given time. This also results in irregularities in the volume removed in the repair area.

FIG. 13 illustrates a repair policy generation system according to embodiments described herein. The repair strategy generator 1300 receives information from one or more data sources and generates a repair strategy for a defect based on the received information regarding defects present on the vehicle. The goal of the repair strategy is to adequately remove the defect and adequately blend the repair surface with the orange peel texture of the vehicle, so that the visibility and detectability of the human eye is reduced.

The repair strategy generator 1300 has an abrasive product retriever 1302 in communication with an abrasive product database 1340. In one embodiment, the abrasive product database 1340 includes information about the current abrasive products 1342 on the active repair system. The abrasive article 1342 has a grade 1344 and other characteristics 1348, such as size. In some embodiments, the abrasive product database may also have disc life information 1346 for the abrasive article 1342. Abrasive product retriever 1302 can retrieve all of this information regarding current abrasive 1342 as well as potential new abrasive product 1343, which can be replaced with current abrasive product 1342.

The repair policy generator 1300 also includes a defect retriever 1306. Defect retriever 1306 is in communication with defect database 1390. Defect database 1390 includes information about defects on vehicles, including defects evaluated by repair strategy generator 1300. A given defect may have one or more feature vectors 1391 that succinctly describe the characteristics of the defect via real numbers and/or classification, and may have a coordinate position 1392 on the vehicle. For example, the defect database 1390 may also have a pre-repair image 1393 of a defect, for example, captured by a vision system. The defect database 1390 may have other information 1394 about the defect of interest as well as information about other defects, such as similar defects, repair trajectories for repairing similar defects, and evaluations of those repairs.

The defect selector 1308 selects a defect or series of defects to be repaired by the repair system. Not all defects need to be repaired. For example, if a defect on the surface of the vehicle is not visible to a potential customer, repair may not be required. The defect selector 1308 selects each defect that needs to be repaired so that the defect repair policy generator 1350 generates repair instructions. In one embodiment, repair instructions are generated one at a time for a plurality of defects, and each repair instruction is sent individually to a repair robot. In another embodiment, the defect repair strategy generator 1350 generates a single track that addresses each of the identified defects for repair.

The repair strategy generator also communicates with a vehicle database 1395 using a vehicle data retriever 1310. The vehicle data retriever 1310 retrieves information about a vehicle undergoing inspection and repair. The vehicle has a surface mesh 1396 that includes a discrete representation of the geometry of the vehicle surface. The vehicle may also include one or more features 1397, including make, model, color, paint layer and treatment number of doors, details, or other modifications. The vehicle may also have one or more parameters 1398, including the presence and texture of orange peel on the surface. The vehicle database may also store other information 1399.

Repair policy database 1320 includes information that may be helpful in evaluating defects and generating policies for repair. The repair strategy database 1320 includes information about the defect, including the defect type 1322 and the location 1324. The repair strategy database 1320 also includes information about orange peel 1326 present near the defect to be repaired. The repair strategy database 1320 may also include other information, including defect regions on the work surface of the vehicle.

Defect repair strategy generator 1350 receives information retrieved by abrasive product retriever 1302, defect retriever 1306, defect selector 1308, vehicle data retriever 1310, and repair strategy database 1320 to generate repair instructions 1364 to be communicated to the robotic repair unit.

Repair instructions 1364 include the shape 1376 that the robotic end effector will form during repair. The shape 1376 may be a fixation point so that the tool remains fixed during repair. In another embodiment, the shape 1376 includes moving the end effector such that the bolster and abrasive product are drawn across the vehicle working surface in a shape. In one embodiment, the shape 1376 may comprise a circle having a radius greater than a radius of the support pad. In another embodiment, the shape 1376 may comprise an ellipse. In other embodiments, the shape 1376 may also include a rose shape, a epitrochoid shape, an endotrachoid shape, or another polygon, such as a rectangle, square. In some embodiments, shape 1376 may also include irregular shapes, such as shapes with curved or straight edges, concave or convex portions, or other features.

The defect repair strategy generator 1350 includes a position generator 1352 that generates a starting position of the abrasive tool for the repair trajectory. The generated starting position may be the same as the end position of the generated trajectory, or it may be different.

The defect repair strategy generator 1350 also includes a trajectory force profile generator 1354 that generates a force 1374 to be applied to the support pad at each point along the trajectory. In some embodiments, the force 1374 may be applied uniformly at each point in time during the repair trajectory. In some embodiments, the force 1374 may be applied evenly on the support pads during the repair trajectory. In other embodiments, the force 1374 is different at different times 1370 during repair, e.g., in repair, the force is initially higher at the repair time 1370a than at a later time 1370 b. Additionally, the end effector may tilt the support pad such that a gradient force 1374 is applied against at least a portion of the repair. The gradient force 1374 may change during repair such that the slope is different at time 1370a than at time 1370 b.

The defect repair strategy generator 1350 also includes a trajectory speed profile generator 1358. The trajectory velocity profile generator 1358 generates a velocity 1378 at which the support pad is moving at each point in the repair time 1370a-1370 n. For example, in a circular trajectory, the end effector may move the support pad more quickly during a first portion of the rotation than a second portion of the rotation.

In some embodiments, defect repair strategy generator 1350 further includes an abrasive disc replacement decision device 1360. In some embodiments, the repair instructions 1364 may also include instructions for the repair robot to replace the abrasive disc or back-up pad before the next defect repair begins. In one embodiment, the disk change decision device 1360 determines whether to change disks based on the disk life indication 1346. Disc life indication 1346 can be, for example, a measure of the abrasive material remaining on the abrasive disc, or can be based on the number of repair cycles completed with a given abrasive article.

The repair instruction 1376 is sent by the repair instruction communicator 1362 to the repair unit 1380. The repair order communicator 1362 may communicate with the repair unit 1380 using a wired connection or a wireless connection. In some embodiments, the repair strategy generator 1300 is part of the repair unit 1380 such that the repair instruction communicator 1362 directly transmits instructions to the force controller and end effector, which effect the repair.

For a series of time points 1370a-1370n, the repair instructions 1364 include the orientation 1372 of the support pad on the working surface within the shape 1376 of the repair trajectory, the force 1374 to be achieved by the force controller, and the velocity 1378 of the abrasive tool.

After the repair unit 1380 completes the repair, in some embodiments, the repair characteristics 1381 are collected. Some repair characteristics (such as the perimeter 1382 and the volume 1384) may be predicted based on the repair strategies generated by the defect repair strategy generator 1350 and verified as part of collecting the repair characteristics 1381. The repair characteristic may also include a degree of feathering 1386. For example, feathering 1386 should occur along the perimeter of the repair area. In some embodiments, the feathering 1386 is substantially uniform around the entire perimeter. In some embodiments, other repair characterizations 1388 may also be captured, including post-repair imaging.

FIG. 14 illustrates a method of generating a repair instruction in an embodiment of the invention. The method 1400 may be implemented in one of the systems described in embodiments herein, or in another suitable system.

In block 1410, vehicle parameters are retrieved. The vehicle parameter relates to the vehicle being prepared for repair. The vehicle may have an associated surface mesh 1412. Retrieving vehicle parameters may also include retrieving characteristics about the paint applied to the vehicle, including layer, amount, curing conditions, and hardness, as indicated in block 1414. The orange peel characteristics 1416 may also be retrieved for the entire vehicle or for a localized portion surrounding one or more defects on the vehicle.

In block 1420, the defect is characterized. In some embodiments, a vehicle may have a plurality of defects, at least some of which are characterized for repair. Characterizing a defect may include a defect type 1421, defect severity 1422, or location 1423 on the vehicle. For example, defect type 1421 may include a stain or scratch. Defect severity 1422 may refer to an area on the working surface affected by the defect, the length of the defect, the height or depth of the defect, or another characteristic. The defect location may comprise a coordinate location on the work surface of the vehicle. Characterizing the defect may also include a depth 1424 of the defect relative to the working surface or relative to a paint layer, such as whether the defect is located in a paint layer or a varnish coating. Characterizing the defect may also include retrieving a pre-repair image 1426 of the work surface. Other characteristics 1428 related to the defect may also be retrieved.

In block 1430, the defects are mapped to a repair strategy. In one embodiment, mapping the defect to a repair strategy includes a repair strategy generator, such as the repair strategy generator of FIG. 13, that receives information about the vehicle and the defect and generates a repair trajectory for the defect based on the received information.

In block 1440, a path is generated for the repair policy. The path may include one or more orientations 1442. In one embodiment, orientation 1442 corresponds to a regular shape, including a circle, an ellipse, a rose, an epitrochoid, or an epitrochoid. In another embodiment, orientation 1442 corresponds to an irregular shape. The shape may include a curvature or a straight line, convex or concave portion, or other feature. Generating a path in block 1440 may also include generating one or more orientations 1444. For example, the support pad may uniformly contact the work surface such that a uniform pressure is applied to the surface of the support pad and onto the work surface. In another embodiment, the support pad is inclined to at least a portion of the generated path. In some embodiments, the inclination may be inward or outward, and may change during repair.

In block 1450, the generated path is temporally parameterized to generate a repair trajectory. Parameterizing the path time includes assigning a velocity and an acceleration along the generated path. The generation time parameterization requires that dynamic constraints be satisfied, as indicated in block 1452, such as the maximum speed and acceleration achievable by the end effector tool, as well as the robot itself, and jerk. The temporal parameterization may also include verifying constraints after generating the trajectory to ensure that the robot and end effector can achieve the trajectory.

In block 1460, repair instructions including a temporal parameterization are sent to the robot to implement the defect. In one embodiment, the instructions may be automatically issued based on a time parameterized completion. In another embodiment, the method 1400 repeats, as indicated by arrow 1470, and a repair trajectory is generated for the second defect. Alternatively, as indicated in fig. 14, the method 1400 may be repeated for a series of defects and a complete trajectory set for vehicle repair before sending instructions.

FIG. 15 is a block diagram of a defect detection and sorting system architecture. Remote server architecture 1500 illustrates one embodiment of an implementation of defect detection and sorting system 1510. By way of example, the remote server architecture 1500 may provide computing, software, data access, and storage services that do not require the end user to know the physical location or configuration of the system delivering the services. In various embodiments, the remote server may deliver the service over a wide area network (such as the internet) using an appropriate protocol. For example, remote servers may deliver applications over a wide area network, and they may be accessed through a web browser or any other computing component. The software or components shown or described in fig. 1-8 and corresponding data may be stored on a server at a remote location. The computing resources in the remote server environment may be consolidated at a remote data center location, or they may be dispersed. Remote server infrastructures can deliver services through a shared data center even though they appear as a single access point to users. Thus, the components and functions described herein may be provided from a remote server at a remote location using a remote server architecture. Alternatively, they may be provided by a conventional server that is installed directly or otherwise on the client device.

In the example shown in fig. 15, some items are similar to those shown in the previous figures. Fig. 15 specifically illustrates that the repair policy generation system may be located at a remote server location 1502. Thus, the computing device 1520 accesses those systems through the remote server location 1502. The operator 1550 may also use the computing device 1520 to access the user interface 1522.

FIG. 15 also depicts another example of a remote server architecture. Fig. 15 shows that it is also contemplated that some elements of the system described herein are disposed at a remote server location 1502 while other elements are not. By way of example,

storage

1530, 1540, or 1560 or repair system 1570 may be provided at a location separate from location 1502 and accessed through a remote server at location 1502. Wherever they are located, they may be accessed directly by computing device 1520 over a network (wide area network or local area network), hosted at a remote site by a service, provided as a service, or accessed by a connectivity service residing at a remote location. Moreover, the data can be stored in substantially any location and accessed or forwarded to the parties intermittently. For example, a physical carrier wave may be used instead of or in addition to an electromagnetic wave carrier wave.

It is also noted that the elements of the systems described herein, or portions thereof, may be provided on a variety of different devices. Some of these devices include servers, desktop computers, laptop computers, embedded computers, industrial controllers, tablet computers, or other mobile devices, such as palmtop computers, cellular phones, smart phones, multimedia players, personal digital assistants, and the like.

FIG. 16 is a simplified block diagram of one illustrative example of a handheld or mobile computing device that may be used as handheld device 16 (e.g., as computing device 1520 in FIG. 15) for a user or client in which the system of the invention (or portions thereof) may be deployed. For example, a mobile device may be deployed in an operator compartment of computing device 1520 for generating, processing, or displaying data. Fig. 17 is another example of a handheld or mobile device.

Fig. 16 provides a general block diagram of components of a client device 1616 that may execute some of the components shown and described herein. The client device 1616 interacts with these components or runs and interacts with some components. In device 1616, a communication link 1613 is provided that allows the handheld device to communicate with other computing devices and, in some embodiments, provides a channel for automatically receiving information, such as by scanning. Examples of communication links 1613 include protocols that allow communication via one or more communication protocols, such as wireless services for providing cellular access to a network, as well as protocols that provide local wireless connectivity to a network.

In other examples, the application may be received on a removable Secure Digital (SD) card connected to the interface 1615. The interface 1615 and communication link 1613 communicate with a processor 1617 (which may also be embodied as a processor) along a bus 1619 that also connects to a memory 1621 and input/output (I/O) components 1623, as well as a clock 1625 and a location system 1627.

In one embodiment, I/O components 1623 are provided to facilitate input and output operations, and device 1616 may include input components (such as buttons, touch sensors, optical sensors, microphones, touch screens, proximity sensors, accelerometers, orientation sensors) and output components (such as a display device, speakers, and/or a printer port). Other I/O components 1623 may also be used.

Clock 1625 illustratively includes a real-time clock component that outputs a time and date. It may also provide timing functions for the processor 1617.

Illustratively, location system 1627 includes components that output the current geographic location of device 1616. This may include, for example, a Global Positioning System (GPS) receiver, LORAN system, dead reckoning system, cellular triangulation system, or other positioning system. It may also include mapping software or navigation software, for example, that generates desired maps, navigation routes, and other geographic functions.

Memory 1621 stores operating system 1629, network settings 1631, applications 1633, application configuration settings 1635, data store 1637, communication drivers 1639, and communication configuration settings 1641. Memory 1621 may include all types of tangible volatile and non-volatile computer-readable memory devices. It may also include computer storage media (described below). The memory 1621 stores computer readable instructions that, when executed by the processor 1617, cause the processor to perform computer implemented steps or functions in accordance with the instructions. The processor 1617 may also be activated by other components to facilitate its functionality.

Fig. 17 shows that the device may be a smartphone 1671. The smartphone 1671 has a touch-sensitive display 1673 that displays icons or tiles or other user input mechanisms 1675. Mechanism 1675 may be used by a user to run applications, make calls, perform data transfer operations, and the like. Generally speaking, smart phones 1671 build on mobile operating systems and provide more advanced computing power and connectivity than feature phones.

It is noted that other forms of the device 1616 are possible.

FIG. 18 is an example of a computing environment in which elements of, or portions of, for example, the systems and methods described herein may be deployed. With reference to fig. 18, an exemplary system for implementing some embodiments includes a general purpose computing device in the form of a computer 1810. Components of computer 1810 may include, but are not limited to, a processing unit 1820 (which may include a processor), a system memory 1830, and a system bus 1821 that couples various system components including the system memory to the processing unit 1820. The system bus 1821 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. The memory and programs described with respect to the systems and methods described herein may be deployed in corresponding portions of fig. 18.

Computer 1810 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 1810 and includes both volatile/nonvolatile media and removable/non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. The computer storage medium is distinct from and does not include a modulated data signal or a carrier wave. It includes hardware storage media including both volatile/nonvolatile and removable/non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, Digital Versatile Disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by computer 1810. Communication media may be embodied by computer readable instructions, data structures, program modules, or other data in a transmission mechanism and includes any information delivery media. The term "modulated data signal" means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal.

The system memory 1830 includes computer storage media in the form of volatile and/or nonvolatile memory such as Read Only Memory (ROM)1831 and Random Access Memory (RAM) 1832. A basic input/output system 1833(BIOS), containing the basic routines that help to transfer information between elements within computer 1810, such as during start-up, is typically stored in ROM 1831. RAM 1832 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 1820. By way of example, and not limitation, fig. 18 illustrates operating system 1834, application programs 1835, other program modules 1836, and program data 1837.

Computer 1810 may also include other removable/non-removable and volatile/nonvolatile computer storage media. By way of example only, FIG. 12 illustrates a hard disk drive 1841 that reads from or writes to non-removable, nonvolatile magnetic media, a nonvolatile magnetic disk 1852, an optical disk drive 1855, and a nonvolatile optical disk 1856. The hard disk drive 1841 is typically connected to the system bus 1821 through a non-removable memory interface such as interface 1840, and optical disk drive 1855 is typically connected to the system bus 1821 by a removable memory interface, such as interface 1850.

Alternatively or in addition, the functions described herein may be performed, at least in part, by one or more hardware logic components. By way of example, and not limitation, illustrative types of hardware logic components that may be used include Field Programmable Gate Arrays (FPGAs), application specific integrated circuits (e.g., ASICs), application specific standard products (e.g., ASSPs), system on a chip (SOCs), Complex Programmable Logic Devices (CPLDs), and the like.

The drives and their associated computer storage media discussed above and illustrated in FIG. 18, provide storage of computer readable instructions, data structures, program modules and other data for the computer 1810. In FIG. 18, for example, hard disk drive 1841 is illustrated as storing operating system 1844, application programs 1845, other program modules 1846, and program data 1847. Note that these components can either be the same as or different from operating system 1834, application programs 1835, other program modules 1836, and program data 1837.

A user may enter commands and information into the computer 1810 through input devices such as a keyboard 1862, a microphone 1863, and a pointing device 1861, such as a mouse, trackball or touch pad. Other input devices (not shown) may include a joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 1820 through a user input interface 1860 that is coupled to the system bus, but may be connected by other interface and bus structures. A visual display 1891 or other type of display device is also connected to the system bus 1821 via an interface, such as a video interface 1890. In addition to the monitor, computers may also include other peripheral output devices such as speakers 1897 and printer 1896, which may be connected through an output peripheral interface 1895.

The computer 1810 operates in a networked environment using logical connections, such as a Local Area Network (LAN) or a Wide Area Network (WAN) to one or more remote computers, such as a remote computer 1880.

When used in a LAN networking environment, the computer 1810 is connected to the LAN 1871 through a network interface or adapter 1870. When used in a WAN networking environment, the computer 1810 typically includes a modem 1872 or other means for establishing communications over the WAN 1873, such as the Internet. In a networked environment, program modules may be stored in the remote memory storage device. Fig. 18 illustrates that remote application programs 1885 may reside on remote computer 1880, for example.

A repaired area on a working surface is presented. The repaired area includes a repair boundary. Within the repair boundary, the working surface has a repair texture, and outside the repair boundary, the working surface has a working surface texture. The repaired area also includes a repair depth distribution within the repair boundary and hidden features. The repaired area is the result of performing a robotic repair on the work surface to remove the defect.

The repaired area may be the result of a grinding operation on the working surface. The grinding operation may have removed the working surface texture from a portion of the repaired area.

The repair boundary may be rotationally symmetric. The repair boundary may have n-fold rotational symmetry, where n is finite and greater than or equal to 2. The repair boundary may have n-fold rotational symmetry, where n is greater than or equal to 2 and less than or equal to 25. The repair boundary may have n-fold rotational symmetry, where n is greater than or equal to 3 and less than or equal to 25. The repair boundary may have n-fold rotational symmetry of the repair boundary, where n is greater than or equal to 3 and less than or equal to 8.

The repair boundary may be an epitrochoid or an endotrachoid. The repair boundary may be defined to have an a-parameter and an h-parameter, and both the a-parameter and the h-parameter are non-zero.

The repair area may be implemented such that the path of the performed robotic repair is an epitrochoid or an endotrachoid. A path is defined to have an a-parameter and an h-parameter, and both the a-parameter and the h-parameter are non-zero.

The repair boundary may be asymmetric.

The repair boundary may be one-sixth of the effective tool radius.

The repair boundary may be one-quarter of the effective tool radius.

The repair boundary may be one third of the effective tool radius.

The repair boundary may be one-half of the effective tool radius.

The repair area may be implemented such that the depth of cut monotonically decreases radially outward from the center of the repaired area.

The repair area may be implemented such that defect residues remain within the repaired area.

The repair area may include feathering.

The repair area may be blended into the working surface.

The repair area may not be apparent to a human.

The repair border may have a convex portion or a convex portion.

The repair boundary may include a straight line.

The repair area may be implemented such that the repair depth profile includes a first depth at a first point and a second depth at a second point relative to the working surface. The first point and the second point may be within a repair boundary.

The repair boundary may include a first cut profile at a first point and a second cut profile at a second point. The first cutting profile may be different from the second cutting profile.

The repair area may be implemented such that the first point is closer to the repair boundary than the second point. The first depth may be greater than the second depth.

A method for robotically repairing defects on a work surface is presented. The method includes receiving a surface mesh of a work surface. The method also includes receiving a location of the defect. The position is a coordinate position corresponding to a point on the surface mesh. The method also includes generating a repair map for repairing the defect. The repair map includes a repair orientation and a repair force at the repair orientation. The method also includes generating a temporal parameterization of the repair map. The method also includes sending a repair instruction to the repair robot. The repair instructions include a repair map and a temporal parameterization. The repair robot includes a tool configured to contact the defect and abrade the work surface at the location of the defect. The repair orientation includes an orientation of the tool, and the force includes a force exerted by the tool on the work surface.

The method may be practiced such that the tool is coupled to a back-up pad that is coupled to the abrasive article. The tool may have a repair orientation in the repair orientation. The repair orientation may include an orientation of the tool relative to the working surface. The orientation may be an outward inclination and an inward inclination or a flush inclination with respect to the working surface.

The method may be implemented such that the repair orientation is a first repair orientation and the repair orientation is a first repair orientation. The repair instructions may also include the tool being at a first repair position at a first time, having a first applied repair force, in a first repair orientation; and the tool is in a second repair orientation at a second time, with a second applied repair force, in a second repair orientation.

The method may be implemented such that the first repair orientation is different from the second repair orientation.

The method may be implemented such that the first repair orientation is the same as the second repair orientation.

The method may be implemented such that the first applied restorative force is the same as the second applied restorative force.

The method may be implemented such that the first applied restorative force is different from the second applied restorative force.

The method may be implemented such that the tool has a moving part, and wherein the repair instruction comprises a tool speed of the moving part.

The method may be implemented such that the repair instruction further comprises a first tool speed at a first time and a second tool speed at a second time. The first tool speed and the second tool speed may be the same.

The method may be implemented such that the repair instruction further comprises a first tool speed at a first time and a second tool speed at a second time. The first tool speed and the second tool speed may be different.

The method may be implemented such that the tool is a rotary sander and the tool speed is the rotational speed.

The method may be implemented such that the tool is a vibratory sander and the tool speed is the vibration rate.

The method may be practiced such that the tool is an orbital sander having an orbit and the tool speed is a rotational orbital speed.

The method may be implemented such that the tool is a random orbital sander having an orbit and the tool speed is a rotational orbital speed.

The method may be practiced such that the tool is a random orbital sander having an axis of motion and the tool speed is an axial speed.

The method may be implemented such that the repair map comprises an ordered plurality of locations, and wherein the temporal parameterization comprises the tool passing through the ordered plurality of locations in sequence.

The method may be implemented such that the ordered plurality of positions form an open path such that the starting position is different from the ending position.

The method may be implemented such that the ordered plurality of orientations form a closed path such that the starting orientation is the same as the ending orientation.

The method may be implemented such that the plurality of orientations cause the tool to trace out the shape.

The method may be implemented such that the shape is a regular shape selected from the group consisting of: circular, oval, polygonal, rose-shaped, epitrochoid, or endostrochoid.

The method may be implemented such that the shape is an irregular shape having a convex portion, a concave portion, a straight portion, or a curved portion.

The method may be implemented such that the repair instruction comprises a command for the repair robot to execute the repair instruction.

The method may be implemented such that the repair instructions further include a command to exchange the abrasive article for a new abrasive article.

The method may be implemented such that the command is based on the received abrasive article parameters. The abrasive article parameter may be an abrasive grade or an abrasive article remaining life.

The method may be implemented such that a repair area including an area on the working surface abraded by the tool is larger than an area of the back-up pad coupled to the tool.

The method may be implemented such that the repair area has an abrasive depth profile across the repair area, and wherein the abrasive depth profile is non-uniform across the repair surface.

The method may be implemented such that a first grinding depth at a first point relative to the working surface is shallower than a second grinding depth at a second point.

A repair robot for repairing a defect on a work surface is presented. The repair robot has a robotic arm having a base at a first edge and a flange at a second end. The repair robot also has a force control coupled to the flange. The repair robot also has an end effector coupled to the force control. The repair robot also has a tool coupled to the end effector. The rehabilitation robot also has a support pad coupled to the tool. A back-up pad is also coupled to the abrasive disc. The repair robot also has a robot controller configured to cause the torque arm to move the tool into a position over the defect and to execute a repair trajectory in response to the received repair instruction. The repair trajectory includes a repair path on the tool-tracked work surface. The repair path includes a plurality of locations, and includes a tool orientation, a tool force, and a tool velocity at each of the plurality of locations. The repair robot also has computer-implemented instructions that, when executed, cause the repair robot to execute the received repair instructions.

The repair robot may also be implemented such that a first tool orientation at the first tool position is different from a second tool orientation at the second tool position.

The rehabilitation robot may also be implemented such that a first tool force at a first tool position is different from a second tool force at a second tool position.

The rehabilitation robot may also be implemented such that a first tool speed at the first tool position is different from a second tool speed at the second tool position.

A repair robot may also be implemented such that the repair path includes a regular shape.

A rehabilitation robot may also be implemented such that the regular shape is circular, elliptical, polygonal, rose-shaped, epitrochoid-shaped, or endostrochoid-shaped.

The repair robot may also be implemented such that the repair path includes an irregular shape having a convex portion or a concave portion.

A repair robot may also be implemented such that the repair path has rotational symmetry.

A repair robot may also be implemented such that the repair path has no rotational symmetry.

A repair robot may also be implemented such that the repair path is asymmetric.

A repair robot may also be implemented such that the abrasive disc is removable and the repair instructions include instructions to remove the current abrasive disc and place a new abrasive disc on the back-up pad.

A repair robot may also be implemented such that the robot controller generates repair instructions based on the defect characteristics. The defect characteristic is a defect type, a defect size, or a defect location on the working surface.

A repair robot may also be implemented such that the robot controller generates repair instructions based on the abrasive disc parameters. The abrasive disc parameter is the grade or remaining disc life.

A repair robot may also be implemented such that the robot controller generates repair instructions based on the working surface parameters. The work surface parameter is a paint parameter or a depth of defect.

It is also possible to implement the rehabilitation robot such that the work surface is a vehicle and wherein the paint parameter is the number of paint coatings, the type of paint coating or the paint hardness.

A rehabilitation robot may also be implemented such that the vehicle is an automobile.

A repair robot may also be implemented such that the base is fixed relative to the car during the repair process.

A repair robot may also be implemented such that the base moves relative to the car during the repair process.

A repair robot may also be implemented such that both the base and the car move during the repair process.

The rehabilitation robot may also be implemented such that the tool is a vibratory sander and the tool speed is a vibration rate of the vibratory sander.

It is also possible to implement the rehabilitation robot such that the tool is a rotary sander and the tool speed is the rotational speed.

A rehabilitation robot may also be implemented such that the tool is an orbital sander having an orbit and the tool speed is the orbital rotational speed.

A rehabilitation robot may also be implemented such that the tool is a random orbital sander with an orbit and the tool speed is the orbital rotation speed.

The rehabilitation robot may also be implemented such that the tool is a random orbital sander with an axis and the tool speed is an axial speed.

A repair instruction for a robotic repair unit is presented. The repair instructions include a starting position of a tool coupled to the robotic repair unit. The tool includes an abrasive article configured to contact and abrade a working surface. The repair instructions also include a repair path including a first position of the tool at a first time and a second position of the tool at a second time. The repair instructions also include a force profile including a first applied force by the robotic repair unit on the abrasive article at a first time and a second applied force by the robotic repair unit on the abrasive article at a second time. The repair instructions may also have a tool speed profile including a first tool speed at a first time and a second tool speed at a second time. The repair instructions may also have computer readable instructions that, when executed, cause the repair robot to execute the received repair instructions.

The repair instructions may also have an ending position of the tool, where the ending position is different from the starting position.

The repair instructions may be implemented such that the working surface includes the defect, and the repair instructions are configured to reduce a visual appearance of the defect on the working surface.

Repair instructions may be implemented such that the perimeter of the repair area is blended into the working surface. Blending may include producing feathering along the edges of the repair area. Blending may include grinding a repair depth profile within a repair area of the working surface.

The repair instructions may be implemented such that a first repair depth at the first location is less than a second repair depth at the second location. The first orientation may be closer to the repair perimeter than the second orientation.

The repair instructions may be implemented such that the abrasive article has an abrasive article area, and wherein the repair area is larger than the abrasive article area.

The repair instructions may be implemented such that the repair area is twice the area of the abrasive article.

The repair instructions may be implemented such that the size of the repair area is twice the diameter of the abrasive article.

The repair instructions may be implemented such that the second orientation is the same as the first orientation.

The repair instructions may be implemented such that the second orientation is different from the first orientation.

The repair instruction may be implemented such that the first force is different from the second force.

The repair instructions may be implemented such that the first tool speed is different from the second tool speed.

The repair instructions may also include a first tool orientation at a first time and a second tool orientation at a second time. The first tool orientation and the second tool orientation may be selected from the group consisting of: flush with the working surface, inclined outwardly relative to the working surface, and inclined inwardly relative to the working surface.

The repair instructions may be implemented such that the first tool orientation is different from the second tool orientation.

The repair instructions may be implemented such that the repair path comprises an open path such that the starting position is different from the ending position.

The repair instructions may be implemented such that the repair path comprises a closed path such that the starting position is the same as the ending position.

The repair instructions may be implemented such that the repair path comprises a regular shape, and wherein the regular shape comprises a circle, an ellipse, a polygon, an epitrochoid, or a rose.

The repair instructions may be implemented such that the repair path has rotational symmetry.

The repair instruction may be implemented such that the repair path is asymmetric.

The repair instruction may be implemented such that the repair path is an irregular path. The irregular path has a concave portion or a convex portion.

The repair instructions may be implemented such that the starting position includes the tool substantially in contact with the defect.

The repair instructions may be implemented such that the work surface is a vehicle.

Repair instructions may be implemented such that the repair instructions are for a repair robot to remain stationary during repair. The working surface may be stationary during the repair. The working surface may be moved during the repair.

The repair instructions may be for a repair robot to move during repair. The working surface may be stationary during the repair. The working surface may be moved during the repair.

The repair instructions may be implemented such that the tool is a vibratory sander and the first speed is a first vibratory rate and the second speed is a second vibratory rate.

The repair instructions may be implemented such that the tool is a rotary sander, the first speed is a first rotational speed, and the second speed is a second rotational speed.

The repair instructions may be implemented such that the tool is an orbital sander having an orbit, and wherein the first speed is a first orbital rotation speed, and wherein the second speed is a second orbital rotation speed.

The repair instructions may be implemented such that the tool is a random orbital sander having an orbit, and wherein the first speed is a first orbital rotation speed and the second speed is a second orbital rotation speed.

The repair instructions may be implemented such that the tool is a random orbital sander having an axis of movement, and wherein the first speed is a first axial speed and the second speed is a second axial speed.

A repair strategy generation system for abrading defects on a work surface is presented. The repair strategy generation system includes a work surface retriever configured to retrieve a surface mesh associated with a work surface. The system also includes a defect retriever configured to retrieve defect characteristics of the defect. The system also includes a repair trajectory generator configured to generate a repair trajectory for grinding the defect based on the defect characteristics. The repair trajectory generator comprises a path generator configured to generate a path for tool execution on the robotic repair unit; a force profile generator configured to generate a force profile for a tool to apply on an abrasive article coupled to the tool; and a temporal parameterizer configured to associate a velocity with the generated path such that at a first time, the tool is in a first orientation and applies the first force, and at a second time, the tool is in a second orientation and applies the second force. The system also includes an instruction communicator configured to communicate the generated repair trajectory to a robotic repair unit for execution. The system also includes a controller having a processor and computer-implemented instructions that, when executed, cause the work surface retriever to retrieve the surface mesh, the defect retriever to retrieve the defect characteristics, the repair trajectory generator to generate a repair trajectory, and the instruction communicator to transmit the generated repair trajectory.

The repair strategy generation system may also include an abrasive product retriever configured to retrieve abrasive article characteristics relating to the abrasive article.

The repair strategy generation system can be implemented such that the abrasive article characteristic is an abrasion grade or remaining abrasive disc life.

The repair strategy generation system may also include an abrasive disc replacement decision generator configured to generate an abrasive article replacement command based on the abrasive article characteristics. The command communicator communicates an abrasive article change command with the generated repair trajectory.

The repair strategy generation system may be implemented such that the instruction communicator further transmits a repair initiation command for the robotic repair unit to execute the repair trajectory upon receipt.

The repair strategy generation system may be implemented such that the instruction communicator also transmits a repair initiation command for the robotic repair unit to execute an abrasive article replacement command prior to executing the repair trajectory.

The repair strategy generation system may be implemented such that the defect characteristic is a pre-repair image of the defect.

The repair strategy generation system may be implemented such that the defect characteristic is a defect type, a defect location on the work surface, a defect depth relative to the surface of the work surface, or a defect size parameter.

A repair strategy generation system can be implemented such that a repair trajectory is generated based at least in part on past defect repairs.

A repair strategy generation system may be implemented such that the work surface retriever also retrieves the work surface characteristics.

The repair strategy generation system may be implemented such that the work surface is a vehicle and wherein the work surface characteristic is an orange peel characteristic.

The repair strategy generation system may be implemented such that the work surface characteristic is a paint characteristic.

The repair strategy generation system may be implemented such that the paint characteristic is paint hardness, paint color, paint layer thickness, number of paint layers, or paint type.

The repair strategy generation system may be implemented such that the defect characteristic is a depth of defect within the paint.

The repair policy generation system may be implemented such that the first orientation and the second orientation are the same.

The repair policy generation system may be implemented such that the first orientation and the second orientation are different.

The repair strategy generation system can be implemented such that a first region of the abrasive article contacting the working surface does not overlap a second region of the abrasive article contacting the working surface. The first region may correspond to the abrasive article in a first orientation, and the second region may correspond to the abrasive article in a second orientation.

The repair strategy generation system may be implemented such that the first applied force is different from the second applied force.

The repair strategy generation system may be implemented such that the first applied force is the same as the second applied force.

The repair strategy generation system can be implemented such that the tool has an orientation relative to the working surface such that a force profile is applied along an area of the abrasive article in contact with the working surface.

The repair strategy generation system may be implemented such that the orientation is an outwardly inclined, inwardly inclined, or flush orientation relative to the working surface.

The repair policy generation system may be implemented such that the repair path is an open path such that the starting position and the ending position of the tool are different.

The repair strategy generation system may be implemented such that the repair path is a closed path such that the starting position and the ending position are the same.

The repair strategy generation system may be implemented such that the repair path is circular, elliptical, polygonal, rose-shaped, epitrochoid, or endostrochoid.

The repair policy generation system may be implemented such that the repair path is irregularly shaped.

The repair strategy generation system may be implemented such that the repair path includes a convex portion.

The repair policy generation system may be implemented such that the repair path includes a concave portion.

The repair policy generation system may be implemented such that the repair path comprises a straight portion.

The repair strategy generation system may be implemented such that the repair path has rotational symmetry.

The repair policy generation system may be implemented such that the repair path is asymmetric.

The repair strategy generation system may be implemented such that the tool is a vibratory sander and the tool speed is a vibration rate.

The repair strategy generation system may be implemented such that the tool is a rotary sander and the tool speed is a rotational speed.

The repair strategy generation system may be implemented such that the tool is an orbital sander having an orbit and the tool speed is an orbital rotational speed.

The repair strategy generation system may be implemented such that the tool is a random orbital sander having an orbit and the tool speed is the orbital rotation speed.

The repair strategy generation system may be implemented such that the tool is a random orbital sander having an axis of movement and the tool speed is an axial speed.

The repair strategy generation system may be implemented such that the tool is coupled to a back-up pad that is coupled to the adhesive article.

A method for generating a repair trajectory for a work surface is presented. The method includes retrieving the work surface parameters using a work surface parameter retriever. The method also includes retrieving defect parameters for the defect on the work surface using a defect parameter retriever. The defect parameters include the location of the defect on the working surface. The method also includes generating a repair path for the defect using a repair path generator. The repair path includes a repair orientation, a repair force, and a repair orientation for the tool contacting the working surface. The method also includes parameterizing the repair path time using a time parameterizer to generate a repair trajectory. The method is implemented by a repair robot controller having a processor and stored computer-implemented instructions that, when executed, cause the controller to perform the steps of retrieving work surface parameters, retrieving defect parameters, generating a repair path, and parameterizing repair path time.

The method may further include transmitting the repair trajectory to a repair robot using an instruction communicator.

The method may further include checking the trajectory for compliance with dynamic constraints of the repair robot. The dynamic constraints include maximum acceleration, maximum velocity, or jerk.

The method may be implemented such that the trajectory includes a first time and a second time. The repair orientation may be a first repair orientation, the repair force is a first repair force, and the repair orientation is a first repair orientation. At a first time, the tool is in a first repair orientation, in a first orientation, with a first repair force. At a second time, the tool is in a second repair orientation in a second repair force.

The method may be implemented such that the first restoring force is the same as the second restoring force.

The method may be implemented such that the first restorative force is different from the second restorative force.

The method may be implemented such that the tool has a moving part. The moving member has a first speed at a first time and a second speed at a second time.

The method may be implemented such that the first speed is different from the second speed.

The method may be implemented such that the first speed is the same as the second speed.

The method may be implemented such that the repair tool is a vibratory sander and the first and second tool speeds are first and second vibration rates.

The method may be implemented such that the repair tool is a rotary sander and the first and second tool speeds are first and second rates of rotation.

The method may be implemented such that the repair tool is an orbital sander having an orbit and the first and second tool speeds are first and second rotation rates.

The method may be implemented such that the repair tool is a random orbital sander having an axis of motion and the first and second tool speeds are first and second axial rates of motion.

The method may be practiced such that the repair orientation is flush with respect to the working surface, inclined outwardly with respect to the working surface, or inclined inwardly with respect to the working surface.

The method may be practiced such that the tool is coupled to a back-up pad, and wherein the back-up pad is removably coupled to the abrasive article and the abrasive article is in direct contact with the work surface.

The method may be implemented such that the method further includes retrieving an abrasive article characteristic and generating a change abrasive article command based on the abrasive article characteristic.

The method may be practiced such that the abrasive article characteristic is an abrasive grade or an indicator of the remaining life of the abrasive article.

The method may be implemented such that the repair path includes a plurality of positions that the tool will pass through when executing the repair path.

The method may be implemented such that the repair path is an open path such that the starting position is different from the ending position.

The method may be implemented such that the repair path is a closed path such that the starting position is the same as the ending position.

The method may be implemented such that the repair path comprises a regular shape selected from the group consisting of: circular, oval, rose-shaped, epitrochoid, endostrochoid, or polygonal.

The method may be implemented such that the repair path comprises an irregular shape having a characteristic selected from the group consisting of: convex portions, concave portions, straight lines and curved lines.

The method may be implemented such that the repair path has rotational symmetry.

The method may be implemented such that the repair path is asymmetric.

The method may be implemented such that the work surface is a vehicle.

The method may be implemented such that the work surface parameter is a paint characteristic of a paint layer on the vehicle.

The method may be implemented such that the work surface parameter is an orange peel texture of the vehicle.

The method may be implemented such that the defect parameter is a defect type.

The method may be implemented such that the defect parameter is a depth of the defect relative to the working surface.

The method may be implemented such that the defect parameter is a pre-repair image of the defect.

The method may be implemented such that the restoring force is selected to cause feathering along the restoration area.

A defect repair trajectory for a repair robot is presented. The trajectory includes a starting position of the tool of the repair robot and an ending position of the tool on the work surface. The tool contacts and abrades the work surface. The trajectory also includes a trajectory shape that includes a first position of the tool at a first time and a second position of the tool at a second time. The trajectory also includes a force profile including a first force applied at a first time and a second force applied at a second time. The trajectory also includes a velocity profile including a first tool velocity at a first time and a second tool velocity at a second time. The trajectory further includes an orientation profile including a first orientation of the tool at a first time and a second orientation of the tool at a second time.

The defect repair track may be implemented such that the first force applied is the same as the second force applied.

The defect repair track may be implemented such that the first force applied is different than the second force applied.

The defect repair trajectory may be implemented such that the first orientation is the same as the second orientation.

The defect repair track may be implemented such that the first orientation is different from the second orientation.

The defect repair trajectory may be implemented such that the first tool speed is the same as the second tool speed.

The defect repair trajectory may be implemented such that the first tool speed is different than the second tool speed.

The defect repair trajectory may be implemented such that the first orientation is different from the second orientation.

The defect repair trajectory may be implemented such that the ending position is different from the starting position.

A defect repair trajectory can be implemented such that the ending position is the same as the starting position.

The defect repair trajectory can be realized such that the trajectory shape is circular, elliptical, rose-shaped, epitrochoid-shaped, endostrochoid-shaped, or polygonal.

The defect repair trajectory can be realized such that the trajectory shape has rotational symmetry.

The defect repair track may be implemented such that the track shape is asymmetric.

The defect repair track may be implemented such that the track shape has a convex or concave portion and a periphery having a curved portion or a straight portion.

The defect repair trajectory may be implemented such that the tool is a rotary sander and the first tool speed and the second tool speed are rotational speeds.

The defect repair trajectory may be implemented such that the tool is a vibratory sander and the first tool speed and the second tool speed are vibration rates.

The defect repair trajectory may be implemented such that the tool is an orbital sander having an orbit, and the first tool speed and the second tool speed are orbital rotational speeds.

The defect repair trajectory may be implemented such that the tool is a random orbital sander having an orbit and the first tool speed and the second tool speed are orbital rotation speeds.

The defect repair trajectory may be implemented such that the tool is a random orbital sander having an axis of movement and the first tool speed and the second tool speed are axial speeds.

A defect repair trajectory may be implemented such that the repair path includes the tool traveling over the defect.

A defect repair trajectory may be implemented such that a defect residue remains after the repair path is performed.

The defect repair trajectory may be implemented such that the work surface is a vehicle and abrading the work surface includes altering the texture of the work surface within the repair area.

The defect repair trajectory may be implemented such that the texture of the working surface within the repair area is different from the texture of the working surface outside the repair area.

The defect repair trajectory may be implemented such that the repair area includes a boundary region where the repair area texture is blended into the work surface texture.

The defect repair trajectory may be implemented such that the boundary region includes feathering.

The foregoing description and drawings are by way of example only and are not intended to limit the illustrative embodiments in any way except as set forth in the appended claims. It is noted that the various technical aspects of the various elements of the various exemplary embodiments that have been described above may be combined in many other ways, all of which are considered within the scope of this disclosure.

Accordingly, although the exemplary embodiments have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible. Accordingly, the present disclosure is not limited to the above-described embodiments, but may be modified within the scope of the appended claims along with their full scope of equivalents.

Examples

Fig. 19 to 23 show some examples of feathering and surface roughness. Fig. 19A to 19E show examples of feathering. Fig. 19A shows a grayscale image of the repaired area on the reflection surface. The polished area 1902 is located on the reflective surface 1904. The repair in fig. 19A shows feathering transition 1910. The width of the exemplary abraded region 1902 is approximately 40 mm. Surface 1904 is varnish coated on top of the painted surface. The darkening of the milled area 1902 indicates a disruption of the reflective surface 1904. This damage is caused by the cutting or smearing of the surface by the abrasive used to remove or reduce the blemish. The abraded area 1902 is significantly larger than the repaired defect.

Once the abraded area 1902 is polished, feathering is important to prevent visible valleys from being evident to individuals viewing the reflective surface. As discussed above, the reflective surface 1904 may have a corrugated surface feature known as "orange peel".

Fig. 19B to 19E show four examples of the treated surface. Fig. 19B shows a non-uniformly feathered abrasive surface with a gradual feathering 1920 on one side and little or no feathering 1930 on the other side. FIG. 19C shows an example 1940 with irregular feathering around the edge. Fig. 19E shows undercut and unbalanced feathering 1970 without feathering 1960. Fig. 19D shows a preferred feathering 1950, which is present uniformly around the perimeter.

The amount of feathering present can be measured by quantifying the damage to the reflective surface on a particular path or area. Fig. 20A and 20B illustrate examples of feathering

measurement techniques

2000, 2050. Fig. 20A shows a line 2002 drawn from the center of the repair area across the feathered transition at the edges. FIG. 20B illustrates an analysis of pixels from FIG. 20A along a line 2002 that extends along an axis 2052 that represents the number of pixels from the center of the image. The pixel value 2054 represents a luminance value of the pixel. As shown, there is a brighter center 2060 that transitions to a darker pixel in the more heavily milled center ring 2065 of milled regions before transitioning to the fully reflective surface 2070.

As shown in fig. 21A-21B, feathering techniques may be used to introduce irregularities or non-uniformities in the milled area. Five

lines

2202, 2204, 2206, 2208, and 2210 are drawn from the center of the treated area to the outer untreated areas. The pixel measurements along the path are shown in FIG. 22B. The effect of feathering is shown by the unevenness 2220 seen in the values of the five samples.

Fig. 22 and 23 mathematically illustrate how feathering may be measured using, for example, surface texture, waviness, and/or roughness in the region across the path.

Fig. 22A shows a repaired area 2300 with a line 2302 drawn from the center to the unground portion. The area was measured over a path 10 pixels wide.

Wherein S _r Is light reflected in the direction of the mirror surface, T _r Is the total reflected flux, R _q Is the root mean square surface roughness, θ is the specular direction, and λ is the wavelength of light. Fig. 22A shows a graph of surface texture 2310, surface waviness 2320, and surface roughness 2330.

Applying equation 10 to FIG. 23A, it can be seen that the transition region has less feathering than necessary, with the root mean square of the roughness being 81.43. Fig. 23B shows higher variability in the region where feathering is present, with the root mean square of roughness being 206.8. The specified roughness range of the orange peel depends on the desired aesthetics of the manufacturer and also on the orientation of the vehicle. For example, a lower panel on a utility vehicle may have orange peel, where the variability of the orange peel exhibits a very tight transition that looks almost like a rough powder coating, which would be expressed as a high roughness number. In another application on the surface of a vehicle hood, orange peel can have a smoother wavy quality, which will be expressed in terms of a lower roughness number.

Fig. 24A and 24B show images of the repair area taken before polishing (fig. 24A) and after polishing (fig. 24B).

Claims

1. A repaired area on a working surface, the repaired defect area comprising:

a repair boundary, wherein within the repair boundary the working surface has a repair texture and outside the repair boundary the working surface has a working surface texture;

a repair depth distribution within the repair boundary;

hiding the feature; and is

Wherein the repaired area is a result of performing a robotic repair on the work surface to remove a defect.

2. The repaired area of claim 1, wherein the repaired area is a result of a grinding operation on the working surface.

3. The repaired area of claim 2, wherein the abrading operation removes the working surface texture from a portion of the repaired area.

4. The repaired region of any one of claims 1-3, wherein the repair boundary is rotationally symmetric.

5. The repaired area of claim 4, wherein the repair boundary can have n-fold rotational symmetry, where n is finite and greater than or equal to 2.

6. The repaired region of claim 4, wherein the repair boundary can have n-fold rotational symmetry, wherein n is greater than or equal to 2 and less than or equal to 25.

7. The repaired region of claim 4, wherein the repair boundary can have n-fold rotational symmetry, wherein n is greater than or equal to 3 and less than or equal to 25.

8. The repaired region of claim 4, wherein the repair boundary can have n-fold rotational symmetry, wherein n is greater than or equal to 3 and less than or equal to 8.

9. The repaired area of any one of claims 1-8, wherein the repair boundary is an epitrochoid or an endotrachoid.

10. The repaired area of claim 9, wherein the repair boundary is defined as having an a-parameter and an h-parameter, and both the a-parameter and the h-parameter are non-zero.

11. A repaired area according to any one of claims 1-10 wherein the path of the performed robotic repair is an epitrochoid or an endotrachoid.

12. The repaired area of claim 11, wherein the path is defined as having an a-parameter and an h-parameter, and both the a-parameter and the h-parameter are non-zero.

13. The repaired area of any one of claims 1-12, wherein the repair boundary is asymmetric.

14. The repaired area of any of claims 1-13, wherein the repair boundary is one-sixth of an effective tool radius.

15. The repaired area of any of claims 1-14, wherein the repair boundary is one quarter of the effective tool radius.

16. The repaired area of any of claims 1-15, wherein the repair boundary is one third of the effective tool radius.

17. The repaired area of any of claims 1-16, wherein the repair boundary is one-half of the effective tool radius.

18. A repaired area as set forth in any of claims 1-17 wherein the depth of cut monotonically decreases radially outward from a center of the repaired area.

19. The repaired area of any one of claims 1-18, wherein a defect residue remains within the repaired area.

20. The repaired area of any one of claims 1-19, wherein the repaired area comprises feathering.

21. The repaired area of any one of claims 1-20, wherein the repaired area is blended into the working surface.

22. A repaired area as set forth in any one of claims 1-21 wherein the repaired area is not apparent to a human.

23. The repaired area of any one of claims 1-22, wherein the repair boundary has a convex portion or a convex portion.

24. The repaired area of any one of claims 1-23, wherein the repair boundary comprises a straight line.

25. The repaired area of any one of claims 1-24, wherein repair depth profile comprises a first depth at a first point and a second depth at a second point relative to the working surface, wherein the first point and the second point are within the repair boundary.

26. The repaired area of any one of claims 1-25, wherein the repair depth profile comprises a first depth at a first point and a second depth at a second point relative to the working surface, wherein the first point and the second point are within the repair boundary.

27. The repaired region of any one of claims 1-26, wherein the repair boundary comprises a first cutting profile at a first point and a second cutting profile at a second point, and wherein the first cutting profile is different than the second cutting profile.

28. The repaired area of any one of claims 1-27, wherein the first point is closer to the repair boundary than the second point, and wherein the first depth is greater than the second depth.

29. A method of repairing a defect on a work surface with a robot, the method comprising:

receiving a surface mesh of the work surface;

receiving a location of the defect, wherein the location is a coordinate location corresponding to a point on the surface mesh;

generating a repair map for repairing the defect, wherein the repair map comprises a repair orientation and a repair force at the repair orientation;

generating a temporal parameterization of the repair map;

sending a repair instruction to a repair robot, wherein the repair instruction includes the repair map and the temporal parameterization; and is

Wherein the repair robot includes a tool configured to contact the defect and abrade the work surface at the location of the defect, wherein the repair orientation includes an orientation of the tool, and the force includes a force exerted by the tool on the work surface.

30. A method for generating a repair trajectory for a work surface, the method comprising:

retrieving the work surface parameters using a work surface parameter retriever;

retrieving defect parameters for a defect on the working surface using a defect parameter retriever, wherein the defect parameters include a location of the defect on the working surface;

generating a repair path for the defect using a repair path generator, wherein the repair path includes a repair orientation, a repair force, and a repair orientation for a tool contacting the working surface;

parameterizing the repair path time using a time parameterizer to generate a repair trajectory; and is

Wherein the method is implemented by a repair robot controller having a processor and stored computer-implemented instructions that, when executed, cause the controller to perform the steps of retrieving work surface parameters, retrieving defect parameters, generating a repair path, and parameterizing the repair path time.